Home ReviewsRefund
Home/Saturn/ION/Saturn ION I (2003-2007)/Repair manual/Cooling System (Mechanical)/Engine Cooling System: Removal & Installation
Contents Wiring diagrams Section: Cooling System (Mechanical) All sections

Engine Cooling System: Removal & Installation Saturn ION I

Cooling System (Mechanical) 1 illustration ~5235 words

Removal Procedure

  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Lower the vehicle.
  3. Reposition the surge tank inlet hose clamp.
  4. Remove the surge tank inlet hose from the surge tank.
  5. Remove the underhood junction block bracket nuts (1,2).
  6. Remove the underhood junction block bracket bolt (3).
  7. Lift the underhood junction block bracket and position away from the surge tank.
  8. Remove surge tank bolt. Lift surge tank and reposition the surge tank outlet hose clamp using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  9. Remove surge tank outlet hose.
  10. Disconnect the coolant level sensor electrical connector.
  11. Remove surge tank.

Installation Procedure

  1. Install the surge tank.
  2. Connect the coolant level sensor electrical connector.
  3. With the surge tank raised, install the surge tank outlet hose.
  4. Reposition the hose clamp using SA9111E to secure the hose. See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Install the surge tank bolt. Tighten: Tighten the bolt to 6.5 N.m (58 lb in).
  6. Set the underhood junction block bracket into position.
  7. Install the underhood junction block bracket nuts (1,2). Tighten: Tighten the nuts to 10 N.m (88 lb in).
  8. Install the underhood junction block bracket bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  9. Install the surge tank inlet hose to the surge tank.
  10. Reposition the hose clamp to secure the hose.
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Remove the bolts from the charge air cooler reservoir.
  2. Using GE-47622 compress the outlet hose clamp at the charge air cooler.
  3. Remove the outlet hose.
  4. Reposition the hose and the reservoir up to allow access to the hose clamps.
  5. Reposition the charge air cooler reservoir hose clamps.
  6. Remove the charge air cooler reservoir hoses from the reservoir.
  1. Install the charge air cooler hoses to the reservoir.
  2. Reposition the hose clamp to secure the hose.
  3. Using GE-47622, compress the outlet hose clamp at the charge air cooler.
  4. Install the outlet hose.
  5. Install the charge air cooler reservoir bolts. Tighten: Tighten the bolts to 8 N.m (70 lb in).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .

Surge Tank Hose/Pipe Replacement - Inlet

CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
  1. Remove the surge tank cap.
  2. Reposition the surge tank inlet hose clamp.
  3. Remove the surge tank inlet hose from the surge tank.
  4. Unclip the surge tank inlet hose from the underhood junction block bracket.
  5. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) in Engine Controls-2.2L (L61).
  6. Unclip the surge tank inlet hose from the fuel rail.
  7. Reposition the surge tank inlet hose clamp.
  8. Remove the surge tank inlet hose from the engine.
  1. Install the surge tank inlet hose to the engine.
  2. Reposition the hose clamp to secure the hose.
  3. Clip the surge tank inlet hose to the fuel rail.
  4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) in Engine Controls-2.2L (L61).
  5. Clip the surge tank inlet hose to the underhood junction block bracket.
  6. Install the surge tank inlet hose to the surge tank.
  7. Reposition the hose clamp to secure the hose.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Lower the vehicle.
  3. Remove the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  4. Reposition the surge tank outlet hose clamp at the engine using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Remove the surge tank outlet hose from the engine.
  6. Reposition the surge tank inlet hose clamp.
  7. Remove the surge tank inlet hose from the surge tank.
  8. Remove surge tank bolt.
  9. Lift surge tank and reposition the surge tank outlet hose clamp using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  10. Remove surge tank outlet hose.
  1. Route the surge tank outlet hose and install the surge tank outlet hose to the engine.
  2. Reposition the hose clamp at the engine to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. With the surge tank raised, install the surge tank outlet hose.
  4. Reposition the hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Install the surge tank bolt. Tighten: Tighten the surge tank bolt to 6.5 N.m (58 lb in).
  6. Install the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  7. Install the surge tank inlet hose to the surge tank.
  8. Reposition the hose clamp to secure the hose.
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Lower the vehicle.
  3. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) in Engine Controls-2.2L (L61).
  4. Reposition the radiator inlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Remove the radiator inlet hose from the radiator.
  6. Reposition the radiator inlet hose clamp at the engine using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  7. Remove the radiator inlet hose from the engine.
  1. Install the radiator inlet hose to the radiator.
  2. Reposition the radiator inlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. Install the radiator inlet hose to the engine.
  4. Reposition the radiator inlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000) in Engine Controls-2.2L (L61).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Partially remove the splash shields from the right fender liner to gain access to the drain cock.
  2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  3. Lower the vehicle.
  4. Reposition the radiator inlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Remove the radiator inlet hose from the radiator.
  6. Reposition the radiator inlet hose clamp at the engine using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  7. Remove the radiator inlet hose from the engine.
  1. Install the radiator inlet hose to the radiator.
  2. Reposition the radiator inlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. Install the radiator inlet hose to the engine.
  4. Reposition the radiator inlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Lower the vehicle.
  3. Reposition the radiator outlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  4. Remove the radiator outlet hose from the radiator.
  5. Reposition the radiator outlet hose clamp at the engine using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  6. Remove the radiator outlet hose from the engine.
  1. Install the radiator outlet hose to the radiator.
  2. Reposition the radiator outlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. Install the radiator outlet hose to the engine.
  4. Reposition the radiator outlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Remove the air intake duct.
  3. Reposition the radiator outlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  4. Remove the radiator outlet hose from the radiator.
  5. Lower the vehicle.
  6. Remove the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  7. Reposition the radiator outlet hose clamp at the engine using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  8. Remove the radiator outlet hose from the engine.
  1. Install the radiator outlet hose to the radiator.
  2. Reposition the radiator outlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. Install the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  4. Install the radiator outlet hose to the engine.
  5. Reposition the radiator outlet hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  6. Install the air intake duct.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  2. Using GE-47622 , compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator.
  3. Remove the charge air cooler radiator inlet hose from the charge air cooler radiator.
  4. Lower the vehicle.
  5. Using GE-47622 compress the charge air cooler radiator inlet hose clamp at the charge air cooler reservoir.
  6. Remove the charge air cooler radiator inlet hose from the charge air cooler reservoir.
  1. Using GE-47622, compress the charge air cooler radiator inlet hose clamp.
  2. Install the charge air cooler radiator inlet hose to the charge air cooler reservoir.
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  4. Using GE-47622, compress the charge air cooler radiator inlet hose clamp.
  5. Install the charge air cooler radiator inlet hose to the charge air cooler radiator.
  6. Lower the vehicle.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  1. Place a drain pan under the front and the center of the vehicle.
  2. Using GE-47622, compress the outlet hose clamp at the charge air cooler.
  3. Remove the outlet hose from the charge air cooler.
  4. Remove the bolts from the charge air cooler reservoir.
  5. Reposition the reservoir and the hose assembly up to gain access to the hose clamp.
  6. Using SA9111E, reposition the outlet hose clamp close to the opposite end of the hose. See «Special Tools»(ref-196980-S01424700812005101000000) .
  7. Remove the charge air cooler outlet hose from the reservoir.
  1. Install the charge air cooler hose to the reservoir.
  2. Reposition the hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  3. Install the bolts to the charge air cooler reservoir.
  4. Using GE-47622, compress the hose clamp to secure the hose.
  5. Install the charge air cooler outlet hose to the charge air cooler.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  2. Using GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler pump.
  3. Remove the auxiliary water pump inlet hose from the charge air cooler pump.
  4. Using GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator.
  5. Remove the auxiliary water pump inlet hose from the charge air cooler radiator.
  1. Using GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose.
  2. Install the auxiliary water pump inlet hose to the charge air cooler radiator.
  3. Using GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose.
  4. Install the auxiliary water pump inlet hose to the charge air cooler pump.
  5. Lower the vehicle.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  2. Using GE-47622 , compress the clamp to the auxiliary water pump outlet hose at the charge air cooler pump.
  3. Remove the outlet hose from the charge air cooler pump.
  4. Lower the vehicle.
  5. Using GE-47622 , compress the clamp at the auxiliary water pump outlet hose at the intercooler.
  6. Remove the outlet hose from the charge air cooler radiator.
  1. Using GE-47622 , compress the clamp to the auxiliary water pump outlet hose to secure the hose.
  2. Install the outlet hose to the intercooler.
  3. Using GE-47622 , compress the clamp to the auxiliary water pump outlet hose to secure the hose.
  4. Install the outlet hose to the charge air cooler pump.
  5. Lower the vehicle.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  1. Place a drain pan under the driver side of the vehicle.
  2. Remove the air intake duct.
  3. Remove the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  4. Using SA9111E , reposition the radiator outlet hose clamp at the engine. See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Remove the radiator outlet hose from the engine.
  6. Remove the oil cooler hoses from the oil cooler.
  7. Remove the oil cooler hoses from the thermostat housing.
  1. Install the oil cooler hoses to the oil cooler.
  2. Install the oil cooler hoses to the thermostat housing.
  3. Install the radiator outlet hose to the engine.
  4. Using SA9111E , reposition the radiator outlet hose clamp at the engine. See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Install the underhood electrical center. Refer to «Underhood Electrical Center or Junction Block Bracket Replacement»(ref-196941-S00992123912005101000000) in Wiring Systems.
  6. Install the air intake duct.
  7. Remove the drain pan from under the vehicle.
  1. Disconnect the cooling fan electrical connector.
  2. Remove the cooling fan wire from the fan shroud.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  4. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator.
  5. Remove the air dam push-in retainers.
  6. Remove the air dam.
  7. Remove the right engine splash shield to radiator mount push-in retainer.
  8. Remove the left engine splash shield to radiator mount push-in retainer.
  9. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  10. Tilt the radiator and condenser forward in the vehicle. Remove the cooling fan assembly from the vehicle.
  1. Tilt the radiator and condenser forward in the vehicle. Install the cooling fan assembly into the vehicle.
  2. Verify that the upper radiator mounts are installed in the vehicle.
  3. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  4. Install the lower radiator mounts, brackets, and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  5. Install the right engine splash shield to radiator mount push-in retainer.
  6. Install the left engine splash shield to radiator mount push-in retainer.
  7. Install the air dam and the push-in retainers.
  8. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator.
  9. Lower the vehicle.
  10. Connect the cooling fan electrical connector.
  11. Install the cooling fan wire to the fan shroud.
  1. Disconnect the cooling fan electrical connectors.
  2. Disconnect the fan relays from the shroud.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  4. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator.
  5. Remove the air dam push-in retainers.
  6. Remove the air dam.
  7. Remove the right engine splash shield to radiator mount push-in retainer.
  8. Remove the left engine splash shield to radiator mount push-in retainer.
  9. Remove the charge air cooler radiator. Refer to «Radiator Replacement - Charge Air Cooler»(ref-196980-S32530325042005101000000) .
  10. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  11. Tilt the radiator and condenser forward in the vehicle.
  12. Remove the cooling fan assembly from the vehicle.
  1. Install the cooling fan assembly into the vehicle.
  2. Restore the radiator and condenser to the original position.
  3. Install the charge air cooler radiator. Refer to «Radiator Replacement - Charge Air Cooler»(ref-196980-S32530325042005101000000) .
  4. Verify that the upper radiator mounts are installed in the vehicle.
  5. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  6. Install the lower radiator mounts, brackets, and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Install the right engine splash shield to radiator mount push-in retainer.
  8. Install the left engine splash shield to radiator mount push-in retainer.
  9. Install the air dam and the push-in retainers.
  10. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator.
  11. Lower the vehicle.
  12. Connect the cooling fan electrical connectors.
  13. Connect the fan relays to the fan shroud.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  2. Remove the bolts that secure the thermostat housing to the water pump feed pipe.
  3. Remove the feed pipe.
  4. Remove the thermostat and retaining sleeve, noting the orientation for installation.
  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
  2. Install the feed pipe that connects the thermostat housing to the water pump.
  3. Install the bolt that secures the water pump feed pipe. Tighten: Tighten the bolt to 10 N.m (18 lb in).
  4. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. If equipped with an automatic transmission, remove the exhaust manifold. Refer to «Exhaust Manifold Removal»(ref-196971-S16920051452005101000000) in Engine Mechanical - 2.2L (L61).
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  4. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tires and Wheels.
  5. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  6. Remove the access plate on the water pump sprocket from the timing cover.
  7. Install J 43651 to the water pump sprocket. See «Special Tools»(ref-196980-S01424700812005101000000) .
  8. Use the access plate bolts to secure J 43651 to the engine front cover. See «Special Tools»(ref-196980-S01424700812005101000000) .
  9. Remove the bolts that secure the sprocket to the water pump.
  10. Remove the bolt (1) that secures the engine block to the water pump.
  11. Remove the bolt (2) that secures the engine front cover to the water pump.
  12. Remove the feed pipe that joins the thermostat housing to the water pump.
  13. Remove the 2 bolts that secure the water pump to the engine block.
  14. Remove the water pump.
  1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
  2. Install the water pump.
  3. Install the 2 bolts that secure the water pump to the engine block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  4. Install the feed pipe that joins the thermostat housing to the water pump. Refer to «Thermostat Replacement»(ref-196980-S39333561662005101000000) .
  5. Install the engine front cover bolt (2) and the bolt (1) that secures the engine block to the water pump. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  6. Install 2 of the bolts that secure the water pump sprocket to the water pump.
  7. Remove the threaded stud.
  8. Install the last bolt. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  9. Remove J 43651 . See «Special Tools»(ref-196980-S01424700812005101000000) .
  10. Install the access plate on the water pump sprocket to the timing cover.
  11. Install the bolts that secure the access plate to the timing cover. Tighten: Tighten the bolts to 10 N.m (18 lb in).
  12. Install the front fender liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000) in Body Front End.
  13. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tires and Wheels.
  14. If equipped with an automatic transmission, install the exhaust manifold. Refer to «Exhaust Manifold Installation»(ref-196971-S30883016912005101000000) in Engine Mechanical - 2.2L (L61).
  15. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Drain the charge air cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  2. Using GE-47622 compress the auxiliary water pump inlet hose clamp at the charge air cooler pump.
  3. Remove the auxiliary water pump inlet hose from the charge air cooler pump.
  4. Using GE-47622, compress the auxiliary water pump outlet hose clamp at the charge air cooler pump.
  5. Remove the auxiliary water pump outlet hose from the charge air cooler pump.
  6. Disconnect the charge air cooler pump electrical connector.
  7. Remove the charge air cooler pump mounting clamp bolts.
  8. Remove the charge air cooler pump.
  1. Install the charge air cooler pump.
  2. Install the mounting clamp bolts to the charge air cooler pump. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  3. Connect the charge air cooler pump electrical connector.
  4. Using GE-47622, compress the auxiliary water pump inlet hose clamp to secure the hose.
  5. Install the auxiliary water pump inlet hose to the charge air cooler pump.
  6. Using GE-47622, compress the auxiliary water pump outlet hose clamp to secure the hose.
  7. Install the auxiliary water pump outlet hose to the charge air cooler pump.
  8. Lower the vehicle.
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .

Drain Cock Replacement

CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  2. Place a drain pan under the right side lower radiator mount.
  3. Remove the radiator drain cock.
  1. Install the radiator drain cock. Tighten the radiator drain cock by hand only.
  2. Lower the vehicle.
  3. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000) .
  1. Remove the cooling fan assembly from the vehicle. Refer to «Cooling Fan and Shroud Replacement (2.2L (L61))»(ref-196980-S32832622732005101000000) or «Cooling Fan and Shroud Replacement (2.0L (LSJ))»(ref-196980-S36227471892005101000000) .
  2. Scribe the position of each of the cooling fan blades on the cooling fan motor shafts.
  3. Remove the cooling fan blade retaining clips and discard.
  4. Remove the cooling fan blades.
  5. Remove the cooling fan motor bolts and remove the cooling fan motors.
  1. Install the cooling fan motors and bolts. Tighten: Tighten the bolts to 8 N.m (70 lb in).
  2. Align the scribe marks on the cooling fan blades and motor shafts.
  3. Install the cooling fan blades.
  4. Install new retaining clips to the cooling fan blades.
  5. Install the cooling fan assembly into the vehicle. Refer to «Cooling Fan and Shroud Replacement (2.2L (L61))»(ref-196980-S32832622732005101000000) or «Cooling Fan and Shroud Replacement (2.0L (LSJ))»(ref-196980-S36227471892005101000000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000)
  2. Lower the vehicle.
  3. If vehicle is equipped with the 2.2L (L61) engine, remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000)
  4. Reposition the radiator inlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  5. Remove the radiator inlet hose from the radiator.
  6. Reposition the radiator outlet hose clamp at the radiator using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  7. Remove the radiator outlet hose from the radiator.
  8. If equipped with an automatic or transaxle, clean the upper transmission oil cooler line connection point and remove the line from the radiator.
  9. If equipped with an automatic or transaxle, remove the left front wheelhouse liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000)
  10. If equipped with an automatic or transaxle, remove the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-196958-S30064356632005101000000)
  11. If equipped with an automatic or transaxle, clean the lower transmission oil cooler line connection point and remove the line from the radiator.
  12. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator and support the cooling fan assembly.
  13. Remove the air dam push-in retainer.
  14. Remove the air dam.
  15. If equipped with air conditioning, remove the condenser bolts.
  16. Slide the condenser down to disengage the upper mounting tabs from the radiator. Position the condenser away from the radiator and support the condenser.
  17. Remove the right and left radiator side baffles.
  18. Remove the right engine splash shield to radiator mount push-in retainer.
  19. If equipped with a manual transaxle, remove the left engine splash shield to radiator mount push-in retainer.
  20. Remove the lower radiator mounts, brackets, and bolts.
  21. Tilt the condenser forward in the vehicle. Remove the radiator assembly from the vehicle.
  22. Remove the upper radiator air baffle.
  1. Verify that the upper radiator mounts are installed in the vehicle.
  2. Install the upper radiator air baffle.
  3. Tilt the condenser forward in the vehicle. Install the radiator assembly into the vehicle.
  4. Verify that the upper radiator mount pins align with the upper radiator mounts.
  5. Install the lower radiator mounts, brackets, and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  6. Install the right engine splash shield to radiator mount push-in retainer.
  7. If equipped with a manual transaxle, install the left engine splash shield to radiator mount push-in retainer.
  8. If equipped with air conditioning, install the right and left radiator side baffles.
  9. Slide the condenser up to engage the upper mounting tabs into the radiator.
  10. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  11. Install the air dam and push-in retainers.
  12. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.
  13. If equipped with an automatic or transaxle, install the lower transmission oil cooler line and seal the radiator. Tighten: Tighten the transmission oil cooler line to 20 N.m (15 lb ft).
  14. If equipped with an automatic or transaxle, install the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-196958-S30064356632005101000000)
  15. If equipped with an automatic or transaxle, install the left front wheelhouse liner. Refer to «Front Fender Liner Replacement»(ref-196958-S29238524142005101000000)
  16. Lower the vehicle.
  17. If equipped with an automatic or transaxle, install the upper transmission oil cooler line and seal to the radiator. Tighten: Tighten the transmission oil cooler line to 20 N.m (15 lb ft).
  18. Install the radiator outlet hose to the radiator.
  19. Reposition the hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  20. Install the radiator inlet hose to the radiator.
  21. Reposition the hose clamp to secure the hose using SA9111E . See «Special Tools»(ref-196980-S01424700812005101000000) .
  22. If equipped with 2.2L (L61) engine, install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-196955-S23042070872005101000000)
  23. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.2L (L61))»(ref-196980-S29591727012005101000000) or «Draining and Filling Cooling System (2.0L (LSJ))»(ref-196980-S13609934402005101000000)
  24. If equipped with an automatic or transaxle, add fluid to the transmission as necessary. Refer to «Transmission Fluid Checking Procedure»(ref-197011-S36605501842005101000000)
  1. Drain the charge air cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  2. Remove the pushpin fasteners from the air dam.
  3. Remove the air dam.
  4. Remove the condenser bolts.
  5. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  6. Reposition the condenser to allow access to the charge air cooler radiator.
  7. Remove the mounting bolt from the lower left side of the charge air cooler radiator.
  8. Remove the mounting bolt from the lower right side of the charge air cooler radiator.
  9. Slide the charge air cooler down to disengage the upper mounting tab from the radiator.
  10. Remove the charge air cooler radiator.
  1. Install the charge air cooler radiator.
  2. Slide the charge air cooler up to engage the upper mounting tab to the radiator.
  3. Install the mounting bolt to the lower right side of the charge air cooler radiator.
  4. Install the mounting bolts to the lower left side of the charge air cooler radiator. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  5. Slide the condenser up to engage the upper mounting tabs into the radiator.
  6. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  7. Install the air dam with the pushpin fasteners.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(ref-196980-S32471759722005101000000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  2. Remove the condenser bolts.
  3. Slide the condenser down to disengage the upper mounting tabs from the radiator. Position the condenser away from the radiator and support the condenser.
  4. Remove the right and left radiator side baffles.
  1. Install the right and left radiator side baffles.
  2. Slide the condenser up to engage the upper mounting tabs into the radiator.
  3. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  4. Lower the vehicle.

Scheme 6

Scheme 6: Removal Procedure
Scheme 6: Removal Procedure
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  2. Remove the condenser bolts.
  3. Remove the lower air dam.
  4. Reposition the condenser to allow access to the charge air cooler.
  5. Remove the bolts from the charge air cooler brackets.
  6. Slide the condenser down to disengage the upper mounting tabs from the radiator. Position the condenser and the charge air cooler away from the radiator and the support.
  7. Remove the right and left radiator side baffles.
  1. Install the right and left radiator side baffles.
  2. Install the charge air cooler.
  3. Install the bolts to the charge air cooler. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  4. Slide the condenser up to engage the upper mounting tabs into the radiator.
  5. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
  6. Install the air dam.
  7. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
  2. Remove the right engine splash shield to radiator mount push-in retainer.
  3. Remove the left engine splash shield to radiator mount push-in retainer.
  4. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator and support the cooling fan assembly.
  5. Remove the air dam push-in retainers.
  6. Remove the air dam.
  7. Support the radiator and condenser. Remove the lower radiator mounts, brackets, and bolts.
  8. Lower the radiator and condenser to access the upper radiator air baffle. Remove the upper radiator air baffle.
  1. Verify that the upper radiator mounts are installed in the vehicle.
  2. Install the upper radiator air baffle.
  3. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  4. Install the lower radiator mounts, brackets, and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  5. Install the right engine splash shield to radiator mount push-in retainer.
  6. Install the left engine splash shield to radiator mount push-in retainer.
  7. Install the air dam and push-in retainers.
  8. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.
  9. Lower the vehicle.
  1. Disconnect the coolant heater cord (1).
  2. Remove the coolant heater bolt.
  3. Remove the coolant heater.
  1. Install the coolant heater.
  2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Connect the coolant heater cord (1).
  1. Disconnect the engine coolant heater cord (1).
  2. Remove the clips from the engine mount and surge tank.
  1. Install the clips from the engine mount and surge tank.
  2. Connect the engine coolant heater cord (1).

More articles — Engine Cooling System